Battery communication system

ABSTRACT

An uninterrupted power supply (“UPS”) system is disclosed which uses a battery communication system to communicate to a UPS processor information concerning the status of a battery pack in an array of parallel coupled battery packs. The battery packs provide back-up power for the UPS system. Information about the battery packs is collected by a monitor associated with each of the battery packs. The monitors measure battery pack voltage, currents and temperature and compile information about the battery pack from the measured values. Each monitor prepares a data word representing information about its battery pack. The data words are transmitted to the UPS in response to commands issued by the UPS processor to the monitors.

CROSS-REFERENCE TO RELATED ACTIONS

This application is a continuation application under 37 CFR §1.53(b) ofapplication Ser. No. 10/784,329, filed on Feb. 23, 2004 now abandoned,which is a continuation of application Ser. No. 09/864,037 now U.S. Pat.No. 6,803,678, filed on May 23, 2001, which is a continuation ofapplication Ser. No. 08/205,527 now U.S. Pat. No. 6,274,950, filed onMar. 3, 1994, entitled BATTERY COMMUNICATION SYSTEM.

This invention relates generally to battery-back up systems forsupplying alternating current (“AC”) or direct current (“DC”) power toelectrical loads. More particularly, this invention relates to methodsand apparatus for collecting information on the status of one or moreback-up batteries and communicating the information to the users ofuninterruptable power supply (“UPS”) systems.

There are numerous types of UPS systems for supplying backup AC or DCpower to a load with batteries or other energy storage devices. The backup power is required when power from an AC power source is performingoutside of acceptable limits or fails completely. UPS systems thatsupply AC power to an AC load, as a back-up to an AC power source, arereferred to herein as AC to AC (“AC-AC”) class UPS systems. Those thatsupply DC power to a DC load, as a back up to an AC power source, arereferred to as AC to DC (“AC-DC”) class UPS systems.

Prior art battery back-up systems have used one very high voltagebattery pack made up of a number of series connected 12 volt automobilebatteries, for example. This battery pack is not very reliable for apower back-up system because the whole battery pack is lost if one ofthe batteries fails and creates an open circuit. It is known to useparallel coupled battery packs to avoid the foregoing problem but evenwhen one of these battery packs fail it is time consuming to identifythe particular one or two or more battery packs that requirereplacement.

Furthermore, in prior art battery pack back-up systems it has beencomplicated to collect and process battery pack voltage and charge anddischarge currents for evaluating the individual battery packs whetherconnected in series or parallel.

The present invention overcomes the limitations of prior art batteryback-up systems by coupling a digital data processor to one or morebatteries or battery packs. The processor is used to gather informationabout the status of an individual battery pack and report theinformation to a user by setting off an alarm. The battery packinformation is also made available for viewing on an LCD display. Inaddition, a communication system is created among at least a singlebattery pack and a main processor associated with the power controlcircuit of a UPS system.

Accordingly, it is an object of the present invention to employ digitalprocessors with a battery to gather information about the batteryincluding whether it is over heating, needs replacement, is capable ofbeing charged, is at float voltage and whether it is a good batterycapable of supplying full power to a load.

Another object of the invention is to identify a battery in a group ofbatteries that requires replacement by coupling a light emitting or anaudio alarm to each battery in the group.

Still another object of the invention is to communicate batteryinformation collected at a battery to a remotely located digitalprocessor such as the processor used in the power control circuit of aUPS system.

It is another object to integrate battery pack information into thecomputer system administrating a UPS system having battery packs forpower back-up.

Yet another object of this invention is to enhance the performance ofbattery packs in UPS systems used with computer, telephone, processcontrol and other down time sensitive electrical loads where loss ofpower means loss of information or service.

Additionally, it is an object to enable a UPS system processor tocommunicate with a monitor associated with each battery in a group ofone or more batteries which are providing back-up power to an electricalload.

Finally, it is an object of the invention to detect a battery pack amonga group of battery packs electrically coupled together that requiresservice and to notify users in advance of trouble so there is time toservice the battery pack, for example, by replacing it with anotherbattery pack.

SUMMARY

The foregoing and other objects of this invention are realized by thepresently disclosed embodiment of a UPS system. The disclosed UPS systemis for an AC-AC class system. It is adaptable for use in an AC-DC classUPS system and with a stand alone group of back-up batteries or batterypacks. The UPS system uses a power control circuit of the type having amulti-tap transformer to pass power from an AC power utility source toan electrical load. An AC line sensor is coupled to the AC source loadto monitor for over and under voltage conditions in addition to totalloss of the line source. A UPS processor is coupled to the line sensorand the transformer to electrically select particular taps on theprimary winding to compensate for under and over voltage conditions. Atriac power switch is also coupled to the line source and the UPSprocessor. The processor de-energizes the triac when it detects that theAC line is about to fail to disconnect the UPS system from the line.When the AC source comes back on the line sensor senses the event andsignals the processor to switch the triac to reconnect the AC source tothe transformer.

The power control circuit includes a MOSFET bridge that is coupled to atertiary winding of the transformer and to the plus and minus voltagebuses connecting a group of 48 volt battery packs coupled together inparallel. The UPS processor supplies 30 khz (approximately) signals tothe gates of the MOSFETs in the bridge to convert the 48 volts DCsupplied by the battery packs to about 48 volts 60 hz AC. The bridgealso functions to convert the 48 volt AC power developed in the tertiarywinding by the AC line source to 48 volt DC for charging the batterypacks.

Battery monitors are packaged inside the housing of each battery pack.Processors on the monitors receive battery pack voltage and charging anddischarging current information. A shunt resistor which is part of themonitor is coupled in series with each battery pack. The voltage andcurrent information along with ambient temperature information areprocessed by the monitor processor and an information packet istransmitted to the UPS processor. Telephone handset lead line and maleand female handset RJ-22 connectors are used to couple the UPS processorto the monitors associated with each of the battery packs.

The UPS processor issues commands to the monitors which regenerate thecommands and send them along to the other monitor. Simultaneously withthe receipt of the UPS command, the monitors send battery packinformation back to the UPS processor. Commands are transmitted to themonitors until the UPS processor detects that it is no longer receivinginformation back. The UPS processor gathers the information and providesit to an LCD display upon user request entered with a three key keypador upon the request of a system administrator from a supervisor computerover a local area network or other communication resource.

THE DRAWINGS

The foregoing objects and other benefits and features of the presentinvention will be even more clearly understood from a further reading ofthe specification together with reference to the drawings which are:

FIG. 1 is a schematic block diagram of the UPS system employing thenovel battery communication system of the present invention.

FIG. 2 is a schematic diagram of the power control circuit of the UPSsystem of FIG. 1 but including more detail.

FIG. 3 is a schematic block diagram of a battery pack monitor of thepresent invention.

FIG. 4 is a schematic diagram of the functional elements of a monitorprocessor software control program which compiles a data wordrepresenting battery back information sent by the monitors to the UPSprocessor.

FIG. 5 is a single flow diagram illustrating the order of execution ofthe software control program that processes battery pack data.

FIG. 6 is a flow diagram of the routine in the monitor software controlprogram that passes information to the UPS processor in response to thereceipt of CLK commands from the UPS processor.

FIG. 7 is a flow diagram of the routine in the UPS processor that issuesCLK commands to the monitors, receives and tests the informationreturned from the monitors for each CLK command and compiles theinformation for further use.

FIG. 8 is a perspective drawing of a battery pack used in the presentUPS system. The dashed lines in the drawing represent the fourindividual batteries within the battery pack housing. Each of the fourbatteries are wired together in series to provide a 48 volt outputacross the battery pack anode and cathode.

DETAILED DESCRIPTION

FIG. 1 shows the novel battery communication system of the presentinvention in combination with an AC-AC class UPS system. The UPS systememploys power control circuits including a multiple tap isolationtransformer, a processor and a MOSFET transistor bridge circuit. Thepower control circuit is one example of an inverter/charger circuit. Thedisclosed battery communication system may be used in combination withboth AC-AC and AC-DC class UPS systems and within each class withsystems that employ other power control circuit types in place of thespecific type chosen for use in the embodiment of system of FIG. 1. TheUPS system of FIG. 1 is representative of all such variations of UPSsystem classes and types.

The UPS system 1 in FIG. 1 includes a housing 2 containing a powercontrol circuit which includes a power sensor circuit 3, a switchingtransformer circuit 4, a UPS processor or cpu 5 and an MOSFET transistorbridge circuit 6 (an inverter/charger circuit). The UPS system furtherincludes the array of parallel coupled, battery packs (or units)represented by battery packs 7 a, 7 b and 7 c and a plurality of batterymonitors 8 a, 8 b and 8 c.

The UPS cpu 5 in combination with the monitors 8 a, b and c and thebattery packs which they serve comprise the presently preferredembodiment of a battery communication system. The battery communicationsystem transmits information concerning the status of the battery packsamong the monitors and the UPS cpu. The underlying information collectedby the monitors includes battery pack charge and discharge current,battery pack temperature and voltage.

The battery units are electrically coupled to the MOSFET bridge at UPShousing terminals 9 a and 9 b and the monitors are electrically coupledto the UPS cpu 5 at housing terminals 10 a and 10 b. An electrical load11 is coupled to the output winding of the multi-tap isolationtransformer circuit 4 at UPS output terminals 12 a and 12 b. The batteryunits 7 a, b and c are specifically located outside housing 2, incontrast to prior art UPS systems, to isolate them from heat generatedby the electrical components within the housing and to facilitate theaddition of extra battery units to the array and/or the removal of oneor more battery units, e. g. a battery pack requiring service.

Referring to FIG. 1, the array of battery packs 7 a, b and c are coupledtogether by the +48 bus line 16 h and the ground bus line 16L. The buses16 h and 16L are coupled to the MOSFET bridge 6 at terminals 9 a and 9 bof the housing 2. The bridge 6 provides charging current to batterypacks 7 a, b and c when the AC line source is supplying power to UPSsystem 1 and to load 11. When the AC line is down, the battery packsprovide +48 volts to the MOSFET bridge which it uses to generate 48 volt60 cycle power which is coupled to load 11 though transformer 4.

The battery communication system extends from the UPS cpu 5 to monitor 8c, the last monitor in the network and the one associated with the lastbattery pack 7 a in the array of parallel battery packs. The lead lines14 a, b and c comprise a command communication path from the UPS cpu 5to monitors 8 a, b and c. The lead lines 15 a, b and c comprise a datacommunication path from the monitors 8 a, b and c to the UPS cpu 5. Eachmonitor couples to the +48 voltage bus 16 h via lead lines 17 a, b and cto obtain battery pack voltage data. The voltage data is used toidentify battery packs that are characterized as early good, asrequiring service and to determine if a battery pack is at floatvoltage, i. e. the battery pack is fully charged.

Each monitor 8 a, b and their associated battery packs 7 a, b and c arecoupled between the +48 volt bus 16 h and the ground bus 16L. Eachmonitor includes a shunt resistor 18 a, b and c which is coupled inseries with the associate battery pack 7 a, b or c at cathodes 20 a, band c. The anodes of the battery packs 7 a, b and c are all coupled tothe +48 volt bus 16 h and one end of each shunt resistor 18 a, b and cis coupled to the ground bus 16L.

Software control programs in UPS cpu 5 and in each monitor processor 64(see FIG. 3), discussed later in connection with FIGS. 4, 5, 6 and 7,make use of the communication paths established between cpu 5 andmonitors 8 a, b and c.

Functionally, UPS system 1 of FIG. 1 couples an AC power source such asa public utility or other power source at its input terminals 13 a and13 b to electrical load 11 at the output terminals 12 a and 12 b of thesystem. The power passed to the load is conditioned by the UPS systempower control circuit if required to compensate for fluctuations in theAC source. The conditioning is accomplished, among other ways, primarilyby switching the ratios of transformer windings passing power to theload.

A further function of the UPS system is to disconnect the AC line sourceat the UPS input terminals 13 a and b the moment that the. UPS systemdetects that the AC source has failed or fallen outside acceptablelevels. On those occasions, the UPS system open circuits the connectionto the UPS input terminals 13 a and b and supplies AC power to load 11generated by the battery packs 7 a, b and c in concert with the UPS cpu5 and MOSFET bridge 6. Similarly, the moment the AC line source isrestored to acceptable levels, the UPS system reconnects the AC sourceat input terminal 13 a and b though to the load 11. The UPS system ispowered by the battery packs when the line source is down.

The novel battery communication system of this invention increases thereliability of the power support function of the UPS system 1 for load11. It does so by determining whether one or more of the battery packs 7a, b or c require service, e.g. replacement, while there is time to doso because AC line power is still available or other battery packs cansupply the load while a battery is being serviced. Each monitor 8 a, band c includes a light emitting diode (“LED”) which emits light toindicate that the battery it is monitoring requires service, e.g.replacement of a bad battery. A bad battery is one that is incapable ofbeing recharged. The light emitted by the LED specifically identifies abattery pack requiring service which is otherwise difficult to locatewithin the battery array.

The monitors are coupled to each other and to the UPS cpu in a mannerpermitting battery information to be passed to the UPS CPU 5 for, amongother purposes, display of a “replace battery” or other service requestmessage on a UPS display screen (see FIG.2, reference number 38). Thebattery data stored at the UPS cpu 5 is also accessible forinterrogation by a remotely located computer over a local and/or widearea network (“LAN” or “WAN”).

The UPS system of FIG. 1 is representative of commercial versions of UPSsystems marketed by American Power Conversion Corporation, the assigneeof this application, under the trade name Matrix UPS systems. The MatrixUPS systems are available in 3000 volt-amp and 5000-volt amp versionswhich generally define mid-size UPS systems. The battery packs (orunits) used in the Matrix UPS systems are sold under the trademark“Smart Cell”. Each Smart Cell includes a monitor and a LED. (See FIG. 8discussed later.)

The system described and claimed herein is not limited to use withmid-size loads but can be scaled up or down to accommodate other loadrequirements.

UPS system 1 is particularly suited for loads such as personalcomputers, servers and minicomputers and is compatible with virtuallyall computer network software operating systems including NetWareavailable from Novell, Notes from Lotus Corporation, OS/400 and OS/2from IBM and VAX/VMS from Digital Equipment Corporation.

Referring now to FIG. 2, the features of the UPS power control circuitare shown in greater detail. The power control circuit includes the ACsource sensor 22, a device for sensing conditions of the AC line sourceincluding when the line source is lost and when the voltage is low orhigh. The sensor 22 detects line voltage, phase, frequency and current.When the AC line source fails, the triac 23 is switched by UPS cpu 5thereby isolating the UPS system from the line source. (In FIG. 1, thefunctions of sensor 22 and triac 23 are represented by the singledevice, sensor 3.) The Sensor and triac are coupled to UPS cpu 5 by leadlines 24 a and b.

The primary winding 25 of transformer 4 is shown with four taps 26 a, b,c, and d which are connected to the moveable switch arms 27 a, b, c andd coupled to a bank of relays 28. The relays are connected to the UPScpu 5 over line 24 c. For normal AC source line values, sensor 22signals CPU 5 to cause the relay bank 28 to close switch arm 27 ccoupling it to tap 26 c. This is a nominal tap position intended tocouple current to load 11 into the secondary winding 29 adequate toprovide AC voltage and current substantially equal to that presented tothe primary winding.

In an overvoltage AC line condition, sensor 22 signals cpu 5 to causerelay bank 28 to close switch arm 27 d to select winding tap 26 d. Tap26 d creates a winding turn ratio between the primary and secondarywindings that reduce the overvoltage to a normal voltage level in thesecondary winding. Conversely, during undervoltage line conditions, a“brownout”, cpu 5 operates the relay bank to close either relay arm 27 aor b depending upon the magnitude of the undervoltage. Taps 26 a and bselect a winding turn ration that causes the transformer to increase thecurrent and voltage appearing at the secondary winding to normal levels.The secondary winding 29 is coupled to the UPS output terminals 12 a andb and the load 11 and includes secondary taps 26 e and f and switch arms27 e and f one of which is selected to switch the output from 220 voltsto 110 volts, for example.

Switching transformer 4 also includes a tertiary winding 30 which iscoupled to the north 31 and south 32 taps of the MOSFET bridge 6. Thewinding turn ratio between the primary and tertiary windings is selectedto provide a voltage in the tertiary winding to be effectively the busvoltage of the array of battery packs 7 a, b and c. In the case of UPSsystem 1, 48 volts is the desired battery bus voltage level. The east 33and west 34 taps of the MOSFET bridge are coupled to the UPS housingterminals 9 a and b and in turn to the battery pack bus lines 16 h and16L.

UPS cpu 5 controls the operation of the MOSFET bridge by applyingsignals to the gates (identified as A, B, C and D) of the individualMOSFETs in bridge 6 at a prescribed frequency that is several magnitudeshigher than the AC line 60 cycle frequency, e.g. 30 Khz.

Cpu 5 is implemented with two processors, the main cpu 36 and theauxiliary cpu 37. The two CPUs are tightly integrated to operate as oneprocessor. CPU 37 shares CPU 37's system clock and is coupled directlyto its data and address buses. The main cpu includes a control programappropriate to control the transformer 4, bridge 6, triac 17 and thebank of relays 23 in response to inputs from the AC line sensor 22.

The auxiliary cpu 37 contains a control program that; communicates withthe control program of main cpu 36; operates the LCD display 38; managesthe communications with the battery monitors 8 a, b and c; and sendsmessages to the LCD display relating to battery service requests andother battery related information provided by the monitors and main CPU36.

The Battery Monitors

The battery monitors 8 a, b and c of FIG. 1 are more fully defined bythe schematic drawing of FIG. 3. The battery monitor of FIG. 3 isrepresentative of all the monitors 8 a, b and c. Monitor 8 c representsthe “n th” monitor attached to the highest numbered or nth battery pack7 c in the array of battery packs. The function of each monitor is thesame regardless of its position in the battery communication systemwhich extends logically and physically from the UPS cpu 5 outward tomonitor 8 c, the last monitor in the daisy chain.

The monitor of FIG. 3 is described using the reference numbersassociated with monitor 8 a, the first monitor in the daisy chain.Monitor 8 a is coupled to UPS cpu 5 (more specifically, to CPU 37) viaCLK command line 14 a and data line 15 a (see FIG. 1).

Referring briefly to FIG. 1, each battery pack is coupled in series witha precision shunt resistor 18 a, in the case of battery pack 7 a. Theelectrical resistance value of the shunt is 0.00025 ohms which providesa voltage drop across it of fifty millivolts under the expected maximumcharging and discharging currents of plus or minus 200 amps. The shuntis therefore a current sensor for monitor 8 a. The shunt is made withMaganin-13, a special alloy designed for this purpose and having a lowtemperature coefficient of resistance. The plus or minus fifty millivoltdrop across the shunt is compatible with the tolerances of thesemiconductor components of monitor 8 a. The shunt resistor isphysically mounted on the battery pack 7 a under discussion and istreated herein as an element of the monitor. The majority of all othercomponents of the monitor 8 a are contained on a small printed circuitboard.

The monitor 8 a includes electrical lead lines 56 a and b which arecoupled to the ends of the shunt resistor 18 a as shown in FIG. 1 andFIG. 3. Lead line 56 a is coupled to the inputs of the non-inverting andinverting, respectively, amplifiers 58 and 60. Lead line 56 b is coupledto a local ground 57 on the printed circuit board of monitor 8 a. Leadline 56 a is coupled to both preamplifiers 58 and 60 to provide separateinput channels for detecting and measuring the discharging and chargingcurrents associated with battery pack 7 a.

The outputs of preamplifiers 58 and 60 are coupled to the analog todigital converter (ADC) section 62 of the monitor processor 64.Processor 64 is the digital processor or controller for the monitor andincludes several analog signal input ports including input ports 64a,b,c and d. The charging and discharging currents from the outputs ofpreamplifiers 58 and 60 are applied to ports 64 a and b, respectively.The +48 volt bus voltage on bus line 16 h is applied to processor inputport 64 d. The +48 bus voltage is also coupled to the power supply 66which supplies +5 and +12 voltage levels for operation of monitor 8 a.An ambient temperature signal produced by the thermistor 68 is appliedto processor port 64 c. The four signals applied to ports 64 a,b,c, andd are in an analog data form.

The ADC section 62 of processor 64 converts the analog data into adigital data format. Processor 64 is a Philips/Signetics 87C752programmable controller, the specification of which, available from themaker, fully describes its operation. The software control programstored in internal read-only memory (“ROM”) of processor 64 controls theoperation of the processor to achieve the described functionality formonitor 8 a. The control program is discussed in detail below and themonitor source code and relevant sections of the UPS cpu 5 controlprogram are listed in full in the microfiche appendix hereto.

Processor 64 also has digital input data ports, two of which areidentified by reference numbers 64 e and f. Input port 64 e on monitor 8a receives digital battery pack data from its adjacent neighbor, monitor8 b, and from all the other monitors in the daisy chain out to monitor 8c. The battery data transmitted from monitor to monitor includes apacket of ten data bits referred to herein as a battery data word.

Input port 64 f of monitor 8 a receives a command signal directly fromUPS cpu 5 in the form of a digital clock signal (“CLK”). Processor 64 onmonitor 8 a immediately re-issues the CLK signal to monitor 8 b therebypropagating the CLK command to successive monitor processors in thechain. Each CLK command in a string of commands propagated along thedaisy chain cause one bit of each monitor's data word to be moved to ortoward UPS cpu 5. The UPS cpu 37 issues CLK signals until it stopsreceiving valid data bits which signals that all the monitors havetransmitted their data words.

The digital output ports of processor 64 include ports 64 p, q, r, s, t,u and v. Processor output port 64 p issues write and read commands toEEPROM 70 to store and retrieve data relating to battery pack 7 a. Theports 64 q and 64 r are issue processor 64 generated chip select (EECS)and clock (EECLK) signals to the EEPROM. Data is shifted into and out ofthe EEPROM serially under the control of the EECLK signals and commands.

The CLK command is issued by the processor at port 64 s in response tothe receipt of the CLK command at input port 64 f. The CLK command istransmitted from monitor 8 a to monitor 8 b, the next one out in thedaisy chain, through the optical isolator 83 and over CLK command line14 b. Thereafter the CLK command passes to successive monitors in thedaisy chain in the same manner.

The battery pack data output port 64 t forwards battery data, DO,information associated with battery pack 7 a directly to UPS cpu 5.Monitor 8 a simultaneously receives battery data, DI, at input port 64e, one bit at a time, from monitor 8 b in response to each successiveCLK command. The battery data associated with successive monitors in thedaisy chain are similarly shifted by the CLK command through monitor 8 ato UPS cpu 5.

Output port 64 u issues a signal to activate or deactive light emittingdiode (“LED”) 50. The LED emits light detectible by the human eye toindicate that the battery pack 7 a associated with monitor 8 a requiresservice, for example replacement.

Output port 64 v issues an AWAKE signal to power supply 66 to keep thepower supply turned “on” after it is initially activated. Processor 64also uses the AWAKE signal to shut down monitor 8 a, i. e. turn themonitor “off” and does so by deactivating the AWAKE signal.

Power supply 66 in monitor 8 a is initially turned “on” by a series orburst of one or more CLK commands which alone or collectively attempt tocharge a bias capacitor in the input section of the power supply. Thelead line carrying the CLK pulse to port 64 f passes through the powersupply. To insure that the power supply in every monitor is activated,the series of CLK commands are immediately followed by a “long pulse”command (also referred to as the wakeup pulse). The CLK commands and thelong pulse are issued by UPS cpu 5 once every second as long as the UPSsystem itself is operational. UPS cpu 5 issues the CLK commands at arate of 1,000 hz.

The burst of CLK pulses ends when UPS cpu 5 detects that the data fromthe last monitor, monitor 8 c, has been received. The long pulse followsthe last CLK command in the burst and remains asserted until theexpiration of a timer in UPS cpu 5 that creates a guard period betweenthe end of the long pulse and the end of the one second cycle.Consequently, the “one second cycle” followed by UPS cpu 5, will belonger than one second when the number of monitors in the daisy chain islarge. The number at which that occurs is related to the number of CLKcommands needed to shift data from the “nth” or last monitor all the wayto UPS cpu 5. At some number of monitors, the length of the CLK commandstring, the duration of the long pulse and the guard period will exceedone second. UPS cpu 5 manages this in a manner as discussed below.

Each monitor processor 64 has an internal timer that measures theduration of the CLK commands received at processor input port 64 f. Theinternal timer is used to filter noise and for verifying the presence ofa long pulse at CLK input port 64 f. However, when a long pulse is atinput port 64 f, Processor delays the generation of the trailing edge ofthe CLK command and thereby regenerates the long pulse at output port 64s. This process is repeated along the daisy chain thereby propagatingthe long pulse, or wake up pulse, to all successive monitors in thebattery communication system.

The long pulse turns the power supply 66 “on” in each of the monitors 8a,b, and c if the first burst of CLK commands failed to do so. Theduration of the long pulse insures that a capacitor within the powersupply is adequately charged to switch a gating transistor that couplesthe +48 bus voltage 16 h to appropriate voltage dividers, one variablevoltage regulator and two fixed voltage regulators within the powersupply once the power supply is on.

The AWAKE signal is part of a “watchdog” function which causes theprocessor 64 to go through a start up cycle if the initial attempt tostart the processor fails. The watchdog function, a subroutine of theprocessor 64 control program also causes the processor to initiate a newstart up cycle, including initializing the power supply, if theprocessor fails to properly execute its control program.

The processor 64 control program includes a thirty-two second internaltimer that begins running after the last CLK signal is received at port64 f, for example, after UPS system shuts down. Upon expiration of thethirty-two second timer, the AWAKE signal is removed from port 64 v andtherefore from power supply 66 shutting down the entire monitor. Thethirty-two seconds prior to shut down provide time for the processor tocomplete program routines in progress including one that stores thebattery status information in EEPROM 70.

The discussion now turns to the optical isolators 82 and 83 coupled tothe monitor data input terminals 80 a and b and the monitor CLK outputports 78 a and b, respectively. Because of large currents present duringcharging and discharging of the battery packs 7 a, b and c, opticalisolators 82 and 83 are placed in series with the command lines 14 a, band c and the battery data lines 15 a, b and c to prevent ground loops.

The CLK command path through monitor 8 a begins at the monitor CLK inputterminals 74 a and b. Input terminal 74 b is grounded while terminal 74a is coupled to processor input port 64 f through power supply 66 asdiscussed above. The CLK path continues at processor output port 64 swhich is coupled to one of two inputs to optical isolator 83. The otherinput to the isolator is coupled to +12 volts. The two outputs of theisolator 83 are coupled to the two monitor CLK output terminals 78 a andb. The terminals 78 a and b are coupled to the CLK input terminals 74 aand b of monitor 8 b, the adjacent neighbor of monitor 8 a presentlyunder discussion. Similarly, the UPS cpu 5 which sends out the CLKcommand includes an optical isolator 83 at its output which couples tomonitor 8 a terminals 74 a and b.

Likewise, except that data passes through a monitor in the oppositedirection to the CLK and long pulse commands, data from monitor 8 benters monitor 8 a at data input terminals 80 a and b both of which arecoupled to the input of optical isolator 82. One of the outputs ofisolator 82 is coupled to processor input port 64 e and the other iscoupled to ground 57. Data passes through the processor to output port64 t which is coupled to amplifier 81 before reaching data outputterminal 88 a. The second data output terminal 88 b is coupled to +12volts. Data output terminals 88 a and b are coupled to data inputterminals 80 a and b in UPS cpu 5, an adjacent neighbor of monitor 8 a.

Command lines 14 a, b and c and data lines 15 a,b and c are implementedas a wire pair in a standard telephone hand set lead line comprising twowire pair (i.e. four wires) terminated at each end with standardtelephone hand set, male, 4 pin RJ-22 connectors. The male RJ-22connectors at the ends of the combined command and data lines mate withfemale connectors on the monitors 8 a, b and c. One wire pair in leadline 14 b connecting monitors 8 a and 8 b are connected to the CLKoutput terminals 78 a and b on monitor 8 a and to the CLK inputterminals 74 a and b on monitor 8 b. The other wire pair in the leadline 14 b connecting monitors 8 a and 8 b are connected to the datainput terminals 80 a and b on monitor 8 a and to the data outputterminals 88 a and b on monitor 8 b. The CLK commands move from monitor8 a to monitor 8 b while the data word moves from monitor 8 b to monitor8 a.

The Battery Packs

Each battery pack 7 a, b and c is a 48 volt battery comprising four,twelve volt lead-acid batteries electrically coupled together in series.The battery packs 7 a, b and c are wired in parallel thereby making itpossible for continued uninterrupted operation of the UPS system 1should one of the battery packs need to be replaced. In contrast, priorart UPS systems employ a single, much higher voltage battery pack thatincludes many smaller batteries coupled together in series. The loss ofjust one series connected battery creates an open circuit that totallycripples the entire string of batteries thereby depriving a load, suchas load 11, of a back up power system.

Another important feature of the UPS system 1 is that the battery packs7 a, b and c are located outside of UPS housing 2 which enclosestransformer 4 and other heat generating components.

Turning now to FIG. 8, the battery packs of the embodiment of FIG. 1 arethe foregoing 48 volt lead-acid battery packs which weigh no more than72 pounds. Other types of batteries based on nickel-iron, ferrous oxide,nickel-cadmium, zinc-air and lithium ion may be substituted for thelead-acid batteries 7 a, b and c. Of course, fuel cells and fly wheelsare other energy storing devices that supply energy in electrical formand may supplement or be substituted for the battery packs.

FIG. 8 shows four, 12 volt lead-acid batteries 40 a, b, c and d with twoof the batteries 40 a and b stacked on top of batteries 40 c and d. Thefour stacked batteries of the present invention are electrically wiredtogether in series (not shown in FIG. 8) to provide a 48 volt outputacross its anode and cathode. The housing 41 enclosing the batteries 40a, b, c and d is closed but ventilated.

A monitor, e.g. monitor, 8 a is physically mounted inside the batterypack housing 41. The housing consists of an upper 42 a and lower 42 bparts that separate for ease of accessing the batteries 40 a, b, c and dand the monitor 8 a. The LED 70 is positioned adjacent a window 43 inthe housing 41 to allow its light to be seen by users when it is turnedon. The parallel voltage buses 16 h and 16 l and the telephone leadlines are coupled to the back side of the monitor.

The 72 pound weight of a battery pack is within weight limits permittingovernight shipment with United Parcel Service (“UPS”), Federal Expressand other courier services. In fact, replacement batteries are shippedto users over night allowing a failed battery to be replaced withintwenty-fours. UPS System 1 users retain the shipping boxes to returnfailed battery packs back to APCC. This shipping process allows UPSsystem 1 users to keep a small (and affordable) inventory of the 48 voltbattery packs for immediate replacement for any failed battery pack. Anunskilled worker can readily be taught to replace a battery pack withone from inventory. The inventory battery pack is replaced by ordering anew battery pack by UPS or Federal Express through a user's normalpurchasing channel. This process eliminates the need to purchase aservice contract to maintain and dispose of the battery packs.

The Stored Control Program in the Monitor Processors (cpu 64)

Turn to FIG. 4 which is a schematic diagram of the function performed bythe processor 64 under the control of its stored control program. Aprimary task of the control program is to compile a packet of data fortransmission to the UPS cpu 5 and to turn on the LED 50 when the batteryassociated with monitor 8 a requires service. In the presently describedembodiment of UPS system 1, the transmitted battery data includes aminimum of six bits that are packaged in a ten bit word, the “dataword”, which is passed over the battery communication system to the UPScpu 5. The other bits include a start bit, a parity bit, a stop bitwhich are supervisory bits and two spare bits available for conveyingadditional information such as the amphere hour capacity of a batterypack.

The data word is compiled from data derived from charging anddischarging currents and the battery pack bus voltage. In addition, thevoltage drop across measured thermistor 68 (FIG. 3) is measured togenerate information on the ambient temperature of the battery pack. Asshown in FIG. 4 (and in FIG. 3), battery pack 8 a charging current, +i,the discharging current, −i, battery pack bus voltage, v, and theambient temperature, Temp, are applied to ADC 62 section of processor64. The ADC outputs of +i, −i and v are averaged by adding 64 successivereadings and dividing the sums by 64. This function is represented asfilter 101. The filter performs the averaging to suppress noiseassociated with the hardware.

The filtered ADC outputs +i and −i are algebraically summed by thesumming amplifier 102 and passed to the integrator 103 provided the 2.3hour logic gates 104 and 105 have indicated that 2.3 hours have elapsedsince monitor 8 a has been on and have detected charging and dischargingcurrent. In addition, the output of gate 105 is fed to the input of gate104 to represent that the summing process will not begin at amplifier102 unless a battery discharge has occurred.

The algebraic sum of the current is integrated by integrator 103 whichrepresents the net amphere hours (“amp hours” or “AH”) delivered by thebattery pack 7 a to load 11. The amp hour output of integrator 103 isapplied to a piecewise, non-linear correction calculator 108 tocompensate for large battery currents which non-linearly reduce theoverall capability of a battery pack to deliver power. The corrected netamp hour calculation is used to perform two tests on battery pack 7 a:the test for generating the “early good bit” in the data word and thetest for generating the “bad battery bit” indicating that battery pack 7a is in need of service, i. e. requires replacement. The corrected, netamp hour output is applied only to the complex comparator section 110 ofcomparator 111.

The other inputs to comparator 111 include the temp output, the +icharging current output and the v or voltage output of the ADC 62. Thevoltage v is applied to both the simple comparator and complexcomparator sections 109 and 110 of comparator 111. The simple comparatorsection 109 compares: the temp input value to a temperature thresholdvalue, e.g. 45 degrees celsius (“C”) and generates the “over temperaturebit” if the threshold is equaled or exceeded; the +i charging currentinput value to a current threshold value, e. g. +2.4 amps and generatesthe “charging bit” if the threshold is equalled or exceeded; the v(voltage) input to a float voltage threshold value, e. g. 54 volts andgenerates the “float bit” if the threshold is equalled or exceeded.

The complex comparator section 110 generates the “early good bit” bycomparing the corrected net amp hours input from calculator 108 to thebus voltage v input from the ADC 62. The complex comparator firstcompares the input v to a bus voltage threshold value, e. g. 52 volts,and proceeds to a second comparison if the bus voltage v is equal to orgreater than the threshold value. The second comparison is a comparisonof the corrected net amp hour input to a threshold value, e. g. 5 AH,and proceeds to generate the “early good bit” if the corrected net amphour input from calculator 108 is equal to or greater than the thresholdvalue.

To generate the “bad battery” bit, the complex comparator 110 makesmultiple comparisons or tests of the corrected net amp hour inputrelative to bus voltage inputs v. If any of these multiple tests fail,the “bad bit” is generated. To begin the first test, the complexcomparator 110 compares the v input to a first threshold value, e. g. 45volts, and proceeds to a second comparator if the v input from the ADC62 equals or exceeds the threshold value. The second comparison comparesthe corrected net amp hours input to a first amp hour threshold, e. g. 2AH, and proceeds to generate the “bad bit” if the corrected net amphours is less than the threshold. The second, third and fourth tests arethe same with the bus voltage v being compared to four other thresholdvalues, e. g. 43, 41 and 39 volts and with the corrected net amp hourinput being successively compared to 4, 6 and 8 amp hours.

One additional bit in the data word transmitted to the UPS cpu 5 is the“large battery bit” loaded into the EEPROM 70 at the factory. The largebattery bit simply identifies a 48 volt battery pack consisting of four12 volt, automobile type, lead acid batteries. The zero state of thisbit indicates that the battery pack under test is a 48 volt battery packmade up of four 12 volt, lead acid batteries which together weigh 72pounds, much less than the four automobile batteries.

The output of comparator 111 includes six data bits identified in FIG. 4which are sent to a register 115 in the processor 64 of each monitor 8a, b and c. The monitor processor control program assembles these sixbits with one spare bit, a start bit, a stop bit and a parity bit tomake up the data word. The data word is transmitted from a monitor 8 a,b or c to UPS cpu 5 in the process described in connection with FIGS. 5,6 and 7.

Stored Control Code in the Monitor Processors

The control program of monitor processor 64 includes four major codesections: an initialization routine; a main program loop; a timerinterrupt service routine; and a communication interrupt serviceroutine.

The Initialization Routine

The initialization routine is run every time a processor 64 is started,i. e., powered up by the on-board power supply 66. The purpose of thisroutine is to set up the processor for the specific functions requiredfor the initialization routine and for other code sections.Initialization includes setting up or initializing the input and outputports 64 a through 64 v, the processor internal timers, loading allconstants and zeroing scratchpad processor RAM memory and write enablingthe EEPROM. In addition, this routine checks if there is an externalrequest to initialize the EEPROM and does so if so requested. Thisroutine also turns on the LED 70 if at an earlier time a bad bit was setto one by monitor 8 a, for example, for the associated battery pack 7 a.

The Main Program Loop

The main program loop runs nearly all the time that processor 64 ispowered up. This section of code is where all the battery data iscollected and analyzed. The data word that is transmitted along thedaisy chain to the UPS cpu 5 is assembled in this section of code. Thedata word includes data bits that represent whether the associatedbattery pack 7 a is “early good” or “bad” along with other data bitsdiscussed above in connection with FIG. 4.

FIG. 5 is a flow diagram depicting the execution of the main looproutine. Upon entry, all scratchpad memory locations are initialized tozero. Next, the routine reads battery pack voltage to a first scratchpadmemory location and adds the value to a second scratchpad memorylocation, all of which were initialized to zero at the start of theroutine. Similarly, discharging and charging currents are read toscratchpad memory and the values are added to separate locations in thescratchpad. The foregoing three steps are repeated 64 times and the sumsare divided by 64. The summing and dividing processes yields averagevoltage, discharge current and charge current values thereby acting assoftware filter for compensating for electrical noise associated withthe voltage and current readings.

Next, the “float bit”, the “charging bit”, and the “over temperaturebit” are set to a one or zero bit in preparation for compiling the dataword. These data word bits along with the “early good” and a “badbattery bit” are generated as described in the above discussion of FIG.5. The “bad battery” determination is the result of one of four tests onthe bus voltage v and the corrected net amp hours as explained abovewith reference to FIG. 4.

The Timer Interrupt Service Routine

The timer interrupt service routine keeps track of all time relatedevents. This interrupt occurs every time the built in timer expires,which has been set by the initialization routine to be every 500microseconds. This means that this routine is executed 2000 times persecond. The functions performed by this routine are: toggle the AWAKEoutput port 64 v (see FIG. 3); detect long pulses (the wakeup pulse) byoverriding the pass through pulse width limiter shown and discussed inconnection with FIG. 6; detect and act on the 32 second period shutdowntimer; write protect the EEPROM; and stop the AWAKE signal to shut downthe monitor 8 a.

Communication Interrupt Service Routine

The communication interrupt service routine handles all communicationbetween the UPS cpu 5 and the other battery packs. The routine executeswhenever the processor 64 detects an incoming CLK command. The immediateresponse of the processor 64 is to transmit the first bit in a data wordto UPS cpu 5 as determined by a state machine. There are 12 states whichcorrespond to the count of an “INDEX” counter. The counter isdecremented from a value 11 to zero in response to each CLK command. Theparticular bit transmitted to UPS cpu 5 is determined by the value ofthe INDEX counter.

Referring to FIG. 6, the flow chart depicts the operation of thecommunication interrupt service routine. Execution begins when the CLKpulse at processor input port 64 f falls from a high to low level (+12volts to 0 volts). If CLK is low for only a short period, exit theroutine because the signal is assumed to be noise. Otherwise, a CLK lowlevel at port 64 f, asserts the leading edge of the CLK signal atprocessor output port 64 s, to monitor 8 b and all successive monitorsin the daisy chain. Based on the value of INDEX, the data word bits aresent in the following order: INDEX 11, the start bit; INDEX 10, the “badbattery bit”; INDEX 9, the “early good” bit; INDEX 8, the “chargingbit”; INDEX 7, the “float bit”; INDEX 6, the “overtemperature bit”;INDEX 5, the “deep discharge bit”; INDEX 4, the “large battery” bit;INDEX 3, a spare bit; INDEX 2, the parity bit; and INDEX 1, the stopbit. INDEX 0, the 12th state of the machine, initializes the loop forthe receipt of the data word from monitor 8 b and successive monitors inthe daisy chain out to the last one.

While the data word of monitor 8 a is being shifted to UPS cpu 5, thedata word of monitor 8 b is being received one bit at a time at theprocessor data input port 64 e. The placement of a received bit into ashift register in processor 64 of monitor 8 a with decrementing INDEX.In addition, the trailing edge of the output CLK pulse is generated andthe communication routine is exited to be restarted upon processor 64 inmonitor 8 a receiving the next input CLK command. The functionrepresented by the block labeled “Reset pulse width limit timer” in FIG.6 is inhibited by the processor 64 when a wakeup pulse is detected atinput port 64 f. Consequently, the wakeup or long pulse command is ableto be propagated along the daisy chain of monitors.

The UPS Processor (cpu5) Stored Control Program in the Auxiliary UPSProcessor (cpu 37)

The UPS auxiliary cpu 37 stores in internal ROM the control program formanaging the LCD display 38 (See FIG. 2), communications with UPS maincpu 36 and 34, communications with the monitors 8 a, b and c. Theroutine for communicating with the monitors gathers and stores statusbits relating to battery packs 7 a, b and c. The information gatheredincludes: the total number of battery packs in the array; the number oflarge battery packs in the array (physically larger than the 72 poundbattery packs); the number of battery packs requiring service, e. g.replacement; the number of battery packs reporting a float condition(“float” voltage refers to the inherent, maximum voltage level to whicha battery can be charged); the number of battery packs reporting an“overtemperature condition”; the number of battery packs reporting thatthey are being charged; and the number of battery packs reporting “earlygood”, meaning that a battery pack is substantially fully capable ofdelivering power to a load.

The routine that handles all battery communication and accounting islocated in the timer interrupt service routine of the auxiliary cpu 37control program. This routine is executed 4000 times per second, orevery 250 microseconds. This routine sets the timing of the outgoing CLKcommand to the battery packs and the return of data bits from themonitors.

Referring to FIG. 7, prior to execution of the monitor communicationroutine, several variables are initialized to specific values. Theimportant ones include: the battery status count is set to zero; themain input counter (“MICNT”) is set to zero; the battery bit counter(“BBCNT) is set to 10 decimal; and the battery scan flag is properly setto indicate to UPS main cpu 36 that the auxiliary cpu 37 communicationroutine is ready. Main cpu 36 enters the communication interrupt looponce every second.

The battery communication and accounting routine, which executes every250 microseconds, is on the top level of a four state, state machine.FIG. 7 depicts the operation of the communication and accountingroutine. A four path state machine is incremented after each executionof this routine. The four functions or states, in proper order, are:

-   -   state 0 Assert the leading edge of the CLK pulse to the battery        packs;    -   state 1 No operation, i. e. a delay period;    -   state 2 Deassert the CLK command to generate the trailing edge        of the CLK pulse; and    -   state 3 Sample, that is receive and read, the data word bits        returned from the array of battery pack monitors 8 a, b and c        and perform the accounting.

States 0 through 2 issue the CLK command to the battery pack monitors 8a, b and c. The gathering and accounting tasks occur during state 3.

Referring to the flow diagram of FIG. 7, the MICNT counter is used togenerate the leading and trailing edges of the CLK command in responseto three, fixed duration timing pulses issued by main cpu 36 toauxiliary cpu 37. The fourth timing pulse from cpu 36 clears the MICNTcounter and the first bit in the data word coming form monitor 8 a isread, i.e. sampled, and stored. The routine is now under the control ofthe BBDAT counter which controls execution. This defines another statemachine that functions as follows (with reference to FIG. 7):

-   -   state 10 The first bit received from monitor 8 a is a start bit.        If the start bit is not valid, the battery pack number counter        is decremented (implicitedly, by a count of one), the battery        pack polling sequence is terminated and the polling or scanning        is reported “done” by properly setting a battery data valid        flag. Thereafter, the communication routine is exited and        control of the scan returns to the main cpu 36 control program.        If the start bit is valid, the BBCNT counter is decremented and        an exit is made to the cpu 36 program.    -   state 9 The second bit received from monitor 8 a is the “bad        battery bit” indicating battery pack 7 a requests service. The        communication routine shifts a “one” bit into a battery input        data buffer BIDAT if monitor 8 a is requesting service, else it        shifts a “zero” bit into the BIDAT buffer, and, in either case,        decrements the BBCNT counter and exits the routine.    -   state 8 The third bit received from monitor 8 a is the “early        good bit”. The communication routine shifts a “one” bit into        BIDAT if monitor 8 a is reporting the presence of an early good        battery pack, else it shifts a “zero” bit into BIDAT and, in        either case, decrements the BBCNT counter and exits the routine.    -   state 7 The fourth bit received from monitor 8 a is the        “charging current bit”. The communication routine shifts a “one”        bit into BIDAT if monitor 8 a is reporting a battery pack that        has been charged, else it shifts a “zero” bit into BIDAT and, in        either case, decrements the BBCNT counter and exits the routine.    -   state 6 The fifth bit received from monitor 8 a is the “float        bit”. The communication routine shifts a “one” bit into BIDAT if        monitor 8 a is reporting a battery pack at float voltage, else        it shifts a “zero” bit into BIDAT, and in either case,        decrements the BBCNT counter and exits the routine.    -   state 5 The sixth bit received from monitor 8 a is the “over        temperature bit”. The communication routine shifts a “one” bit        into BIDAT if monitor 8 a is reporting a battery pack that is        too “hot”, else it shifts a “zero” bit into BIDAT, and in either        case, decrements the BBCNT counter and exits the routine.    -   state 4 The seventh bit received from monitor 8 a is the “large        battery bit”. The communication routine shifts a “one” bit into        BIDAT if monitor 8 a is reporting a battery pack that is the        large rather than the small size, else it shifts a “zero” bit        into BIDAT, and in either case, decrements the BBCNT counter and        exits the routine.    -   state 3 The eighth bit received from monitor 8 a is a spare bit,        a bit available for some yet to be selected data, e. g. a bit        indicating that the battery pack associated with monitor 8 a has        experienced a large discharge. The communication routine shifts        a “zero” bit into BIDAT, decrements the BBCNT counter and exits        the routine.    -   state 2 The ninth bit received from monitor 8 a is a spare bit,        a bit available for some yet to be selected information. The        communication routine shifts a “zero” bit into BIDAT, decrements        the BBCNT counter and exits the routine.    -   state 1 The ninth bit received from monitor 8 a is a parity bit.        The communication routine reads the parity bit then proceeds to        test the validity of the parity bit. If it is invalid, the        parity error counter is incremented by a count of “one”, the        battery pack counter is incremented by a count of “one” to        accumulate the total number of monitors in the battery pack        array, the BBCNT counter is decrement by a count of “one” and        the routine is exited. If the parity bit is valid, the “one”        bits previously shifted into buffer BIDAT are used to increment        their associated counters, the battery pack counter is        incremented, the BBCNT counter is decremented, and the routine        is exited.    -    The counters associated with the BIDAT bits are: a “large        battery pack” counter for counting the total number of large        size battery packs in the array; a “bad battery” counter for        counting the total number of battery packs in the array        requesting service; a “float” counter for counting the total        number of battery packs in the array that are at float voltage;        a “hot” battery pack counter for counting the number of battery        packs in the array that are in an over temperature environment;        a “charging” counter for counting the total number of battery        packs in the array that have reported being charged by the UPS        system; an “early good” counter for counting the total number of        battery packs in the array that have reported that they are        substantially fully charged and are known to have supplied        charge to load 11.    -   state 0 The tenth bit received from monitor 8 a is a stop bit,        the last bit of the ten bit data word received from monitor 8 a.        The stop bit resets the BBCNT counter to 10 in preparation for        restarting the scan and for transmitting the data word        associated with monitor 8 b which now resides in monitor 8 a.        The stop bit is tested, and if good, the routine is exited and        subsequently a new CLK command is generated by states 0, 1        and 2. If the stop bit is invalid, the battery pack counter is        decremented by one and the data received in this data word        packet is invalidated.

There are two other related functions important to the communicationwith the monitors 8 a, b and c that are part of other cpu 36 routines:the battery wakeup pulse routine and the routine for re-enabling thebattery scan routine. The wakeup and re-enable scan routines are part ofthe main program loop of cpu 36. The wakeup routine moves the finalBIDAT and accumulated count data to memory locations where it isavailable for other main cpu 36 and auxiliary cpu 37 routines includingthe LCD display routine. The wakeup pulse routine appends the long pulseto the end of the CLK command stream to insure that all the powersupplies 66 in the monitors 8 a, b and c are activated as discussedabove.

The re-enable routine inhibits the once per second process of issuingCLK command to the monitors when the number of monitors 8 a, b, and c isof a magnitude to cause the normal one second monitor scanning orpolling cycle to exceed one second in duration. This feature wasdiscussed above in connection with the “Reset Pulse WIDTH LIMIT TIMER”shown in FIG. 6.

While the invention has been particularly shown and described withreference to a preferred embodiment thereof, it will be understood bythose skilled in the art that the foregoing and other changes in formand detail may be made therein without departing from the spirit andscope of the invention.

1. A UPS system employing a back-up power system for supplyingelectrical power to a load when power from an AC power source isperforming outside of acceptable limits or fails comprising, incombination a power control circuit, including a UPS processor, forcoupling to an AC power source and to a back-up power system includingone or more battery packs coupled together in parallel for supplyingpower to a load when an AC power source is performing outside acceptablelimits or fails and a battery communication system including, incombination with the UPS processor, a plurality of battery packmonitors, one monitor being associated with one battery pack in theparallel coupled array of one or more battery packs, each monitorincluding a battery processor coupled to its associated battery pack forreceiving, processing and storing battery pack information and acommunication lead line coupled to the UPS processor and the monitorprocessors for transmission of battery pack information among themonitor processors and the UPS processor.
 2. The UPS system of claim 1wherein the transmission of battery pack information from a monitorprocessor to the UPS processor occurs in response to a command issued bythe UPS processor to a monitor processor.
 3. The UPS system of claim 1wherein each monitor includes an alarm for identifying to users of thesystem that a battery pack associated with a monitor requires service.4. The UPS system of claim 3 wherein the alarm includes a light emittingdiode (“LED”).
 5. The UPS system of claim 1 wherein each monitor furtherincludes a power supply for generating voltages for monitor electricalcomponents including the monitor processor wherein the power source forthe monitor power supply is a battery pack and further including aconnector for coupling to a battery pack.
 6. The UPS system of claim 1wherein the communication system extends from the UPS processor to eachmonitor processor associated with a battery pack in the array ofparallel coupled battery packs.
 7. The UPS system of claim 6 whereineach monitor processor that receives a command from the UPS processortransmits battery pack information over the lead line to the UPSprocessor.
 8. The UPS system of claim 6 wherein the communication systemincludes a lead line coupled between the UPS processor and the firstmonitor processor, between the first and second monitor processors andbetween all remaining processors out to the last monitor processor andwherein the UPS processor transmits commands to each monitor processorassociated with a battery pack and each monitor processor associatedwith a battery pack transmits battery information to the UPS processorin response to receipt of a command.
 9. The UPS system of claim 1wherein the communication system includes a command lead line coupledfrom the UPS processor to a first monitor processor and coupled betweenthe first and a second monitor processor and between remaining monitorprocessors associated with a battery pack in the array of parallelbattery packs, a data lead line coupled from the UPS processor to afirst monitor processor and coupled between the first and a secondmonitor processor and between the remaining monitor processorsassociated with a battery pack in the array of parallel battery packs,and wherein the UPS processor transmits a command to each monitorprocessor over the command lead lines directly or through other monitorprocessors coupled to the command lead lines and each monitor processortransmits battery pack information to the UPS processor over the datalead lines, in response to receipt of a command from the UPS processoreither directly or through other monitor processors coupled to the datalead lines.
 10. The UPS system of claim 1 wherein the battery packinformation transmitted to the UPS processor includes information that abattery pack associated with a monitor requires service.
 11. The UPSsystem of claim 1 wherein the battery pack information transmitted tothe UPS processor includes information that a battery pack hasexperienced charging.
 12. The UPS system of claim 1 wherein the batterypack information transmitted to the UPS processor includes informationthat a battery pack has been determined to be early good.
 13. The UPSsystem of claim 1 wherein the battery pack information transmitted tothe UPS processor includes information that a battery pack is at or nearfloat voltage.
 14. The UPS system of claim 1 wherein the battery packinformation transmitted to the UPS processor includes information that abattery pack is over an acceptable temperature.
 15. The UPS system ofclaim 1 wherein the battery pack information transmitted to the UPSprocessor includes information that a battery pack is a large battery.16. The UPS system of claim 9 wherein the command and data lead linesinclude four wire, telephone handset lead terminated at each end with afour pin RJ-22 telephone handset connector.
 17. The UPS system of claim1 wherein the monitor processors are coupled to an associated batterypack to receive, process and store battery charging and dischargingcurrent and voltage data.
 18. The UPS system of claim 1 wherein eachmonitor further includes an LED alarm and wherein the monitor processorsare further coupled to an associated battery to receive, process andstore battery charging and discharging current data and voltage data togenerate information indicating that the battery requires service andfor turning on an LED alarm to identify to users of the UPS system thata particular battery pack in the parallel array requires service. 19.The UPS system of claim 1 further including an LCD display coupled tothe UPS processor and wherein the monitor processors transmitinformation relating to a battery pack for viewing on the LCD display.20. The UPS system of claim 1 wherein the monitor processors are furthercoupled to a temperature sensor to receive, process and store batterytemperature information.
 21. The UPS system of claim 20 wherein thebattery temperature data is processed by a battery monitor to producebattery pack temperate information for transmission to the UPS processorindicating that a battery pack temperature has exceeded a recommendedlevel.
 22. The UPS system of claim 1 wherein each monitor processorcalculates ampere hour information on its associated battery pack anduses the information to determine an early good condition for thebattery pack.
 23. The UPS system of claim 22 herein each monitorprocessor further uses calculated ampere hours information to determinewhether its associated battery pack requires service.